CTI 2500-RBC PROFIBUS REMOTE BASE CONTROLLER INSTALLATION AND OPERATION GUIDE Version 1.2

CTI 2500-RBC PROFIBUS REMOTE BASE CONTROLLER INSTALLATION AND OPERATION GUIDE Version 1.2 CTI Part # 062-00364-012 *062-00364-012* 2500RBCIOG 080309

Copyright 2005 Control Technology Inc. All rights reserved. This manual is published by Control Technology Inc., 5734 Middlebrook Pike, Knoxville, TN 37921. This manual contains references to brand and product names which are tradenames, trademarks, and/or registered trademarks of Control Technology Inc. Siemens and Simatic are registered trademarks of Siemens AG. Other references to brand and product names are tradenames, trademarks, and/or registered trademarks of their respective holders. DOCUMENT DISCLAIMER STATEMENT Every effort has been made to ensure the accuracy of this document; however, errors do occasionally occur. CTI provides this document on an as is basis and assumes no responsibility for direct or consequential damages resulting from the use of this document. This document is provided without express or implied warranty of any kind, including but not limited to the warranties of merchantability or fitness for a particular purpose. This document and the products it references are subject to change without notice. If you have a comment or discover an error, please call us toll-free at 1-800-537-8398 or email us at sales@controltechnology.com. REVISION HISTORY V1.0 04/30/04 Original Issue V1.1 08/25/04 Changed Profibus address switch open/close labeling 05/03/07 Fixed Profibus connector diagram, added 2500 Series processors V1.2 06/22/09 Added reference to WorkShop Profibus configuration documentation V1.21 08/03/09 Corrected Profibus cable impedance typo on p.30 from 135 to 35

PREFACE This Installation and Operation Guide provides reference information for the CTI 2500-RBC Profibus Remote Base Controller. The information in this manual is directed to individuals who will be installing the module and configuring it for use with a Profibus Master. We assume you are familiar with the installation and operation of: 1) CTI 2500 Series and Simatic 505 programmable controllers, 2) PLC WorkShop for Siemens 505 or Com Profibus Configuration Software Please refer to the appropriate user documentation for specific information on your programmable controllers and I/O modules. CTI 2500-RBC Installation and Operation Guide V1.2 i

USAGE CONVENTIONS NOTE: Notes alert the user to special features or procedures. CAUTION: Cautions alert the user to procedures that could damage equipment. WARNING: Warnings alert the user to procedures that could damage equipment and endanger the user.

TABLE OF CONTENTS CHAPTER 1. DESCRIPTION... 1 1.1. Introduction... 1 CHAPTER 2. INSTALLATION... 3 2.1. Installation Planning... 3 Choosing Profibus Media 3 Wiring the Profibus Connector 3 Selecting a Profibus Address 3 Selecting a Profibus Speed 4 Selecting Slave Parameters 4 Setting Module Hardware Options 4 2.2. Power Requirements... 4 2.3. Unpacking the Module... 4 2.4. Configuring the Module... 5 Setting the Module Option Switches 5 Setting the Output State on Communications Loss 9 Setting Software Parameters in WorkShop or Com Profibus 10 Configuring the Remote Base in WorkShop or Com Profibus 10 Exporting a Binary Configuration File from Com Profibus 10 Merging the Configuration File into the Profibus Master 10 2.5. Physical Installation... 10 2.6. Connecting the Profibus Cable... 11 2.7. Diagnostics... 12 2.8. Base Mismatch Handling in the 2500-RBC... 12 2.9. Differences Between the 2500-RBC and the 505-6870... 13 2.10. Diagnostics... 13 PLC Status Words 13 Diagnostic Bytes from the 2500-RBC 14 CHAPTER 3. SETTING UP THE 2500-RBC USING WORKSHOP OR COM PROFIBUS... 17 3.1. Overview... 17 3.2. Startup Com Profibus... 17 3.3. Import the 2500R.gsd file into Com Profibus... 18 3.4. Set Bus Parameters... 19 3.5. Add a Master to the System and Set the Profibus Address.... 20 3.6. Add the 2500-RBC to the System... 23 3.7. Configure the 2500-RBC... 23 3.8. Save the Profibus Configuration and Export the Binary File... 25 3.9. Merge the Binary File in Workshop... 26 3.10. Write the Configuration to the Base(s)... 28 3.11. Select Synchronous or Asynchronous and Start Profibus... 28 APPENDIX A. PROFIBUS INSTALLATION GUIDELINES... 30 General Installation Information... 30 Maximum number of stations 30 Cable Type 30 Cable Lengths 30 CTI 2500-RBC Installation and Operation Guide V1.2 i

Bus termination 31 Bus connectors and PROFIBUS-DP/FMS interface 31 Cable laying guidelines... 33 Laying of copper cable 33 Laying cables within control cabinets 34 Laying cables outside of control cabinets 35 SPECIFICATIONS... 36 General... 36 Ports... 36 Environmental... 36 LIMITED PRODUCT WARRANTY... 38 REPAIR POLICY... 39

CHAPTER 1. DESCRIPTION 1.1. Introduction The CTI 2500-RBC Profibus Remote Base Controller is a member of Control Technology's family of I/O modules compatible with the programmable controllers. The 2500-RBC Profibus Remote Base Controller (RBC) allows a CTI 2500 Series or Simatic 505 I/O base to function as a slave node on a Profibus-DP I/O channel that complies with the PROFIBUS standard (DIN 19245, Part 3). The 2500-RBC is intended to be a replacement for the Siemens 505-6870 RBC. It provides the following functions: Compatible with CTI 2500 Series, Simatic 505, Siemens S5 and S7 masters Can be used in currently-available CTI and Siemens 4-, 8-, and 16-slot bases Supports communication speeds from 9.6 Kbaud (maximum cable distance per segment: 1200 m) up to 12 Mbaud (maximum cable distance per segment: 100 m). Includes an LED display which shows error codes or current station address. Configurability using the Siemens 505-6870 gsd file or the new CTI 2500-RBC gsd file which can be downloaded from our web site The 2500-RBC resides in CTI 2500 Series or Simatic 505 base. It installs in the second slot from the left, adjacent to the power supply module. Figure 1. 2500-RBC Front Panel CTI 2500-RBC Installation and Operation Guide V1.2 1

CHAPTER 2. INSTALLATION The installation of the Model 2500-RBC Profibus Remote Base Controller consists of the following steps: 1) Planning the installation, 2) Verifying power requirements 3) Unpacking and configuring the module, 4) Physical installation, 5) Connecting cables, 6) Checking the module operation. 2.1. Installation Planning Choosing Profibus Media The 2500-RBC attaches directly to the Profibus-DP RS485 cable using a DB9 connector. The Profibus organization recommends using bus cable as specified in EN 50170 part 8-2 and Cable Type A, and should comply with the parameters below. An example cable of this type would be Belden 3079A. For more information on Profibus installation guidelines, see Appendix A. Wiring the Profibus Connector The Profibus connector should be wired as shown in Section 2.6. For more information, refer to Appendix A. Selecting a Profibus Address Before proceeding, you must determine what Profibus address you will assign to the module. Profibus addresses range from 0 to 127. In CTI 2500 Series and Simatic 505 systems, address 0 and addresses 113-127 are not valid. Therefore, any address between 1 and 112 is valid for the RBC when installed in these systems. Note that each slave node and the master must have a unique address on the bus. CTI 2500-RBC Installation and Operation Guide V1.2 3

Selecting a Profibus Speed Before proceeding, you must determine your Profibus operating speed. The 2500-RBC supports Profibus speed from 9.6K bits/s to 12M bits/s. For more information on selecting Profibus speed see Appendix A. Selecting Slave Parameters The 2500-RBC supports four parameterization options. These options are set using WorkShop, or using the properties screen for the remote base in Com Profibus. For more information about these settings, see Setting Software Parameters in Com Profibus in Section 2.4. Setting Module Hardware Options In addition to the Profibus address, the module includes a hardware setting for selecting the state of the base discrete outputs in the event of a communications loss. The module can be configured to set all outputs off, or to leave outputs at their last values. 2.2. Power Requirements The CTI 2500-RBC module consumes 2.5 watts of +5 VDC power from the backplane. Before installing the RBC, verify that your mounting base power budget can accommodate the required power. A good tool for performing the verification is the CTI Replacement Guide and Power Calculator, available from our website at ftp://ftp.controltechnology.com/public/download/tools/ 2.3. Unpacking the Module Open the shipping carton and remove the special anti-static bag that contains the module. After discharging any static build-up, remove the module from the static bag. Do not discard the static bag. Always use this bag for protection against static damage when the module is not inserted into the I/O base. CAUTION: The components on the 2500-RBC module printed circuit card can be damaged by static electricity discharge. To prevent this damage, the module is shipped in a special anti-static bag. Static control precautions should be followed when removing the module from the bag and when handling the printed circuit card during configuration. 4 CTI 2500-RBC Installation and Operation Guide V1.2

2.4. Configuring the Module There are six steps to configuring the module and getting it operational on a Profibus network: 1. Setting the module option switches 2. Setting the output state on communication loss (freeze jumper) 3. Setting software parameters in WorkShop or Com Profibus 4. Configuring the remote base in in WorkShop or Com Profibus 5. Exporting a binary configuration file (Com Profibus only) 6. Merging the configuration file into the Profibus master (Com Profibus only) For detailed information on using Com Profibus to configure a remote base with the 2500-RBC, refer to Chapter 3. option switches freeze jumper setting Setting the Module Option Switches Switches on the 2500-RBC are used to select the following Serial Port Baud Rate Profibus Address Display mode Figure 2. Switch Locations Figure 2 indicates the location of the option switches and freeze jumper. The remainder of this section describes the function of the individual switches. SW1 through SW3 Serial Port Baud Rate. Switches 1-3 are used for setting the baud rate of the serial port. Serial port operations are not currently implemented in the product. Baud rate SW1 SW2 SW3 38400 0 0 1 19200 1 1 1 9600 1 1 0 2400 1 0 0 1200 0 1 0 300 0 0 0 Invalid 0 1 1 Invalid 1 0 1 CTI 2500-RBC Installation and Operation Guide V1.2 5

SW4 through SW10 - Profibus Address Switches 4 through 10 are used to assign a station address to the RBC for identification on the Profibus-DP I/O channel. Each station in the Profibus network must be uniquely numbered. The station address is assigned as a binary number, with SW4 and the most significant bit (MSB) and SW10 as the least significant (LSB). The table below shows how to set the dipswitch to a station address between 0 and 125. Note that a switch in the open position=1 and a switch in the closed position=0. Table 1. Profibus Station Address Settings Station Switch Number / State Station Switch Number / State Addres Address 4 5 6 7 8 9 10 s 4 5 6 7 8 9 10 0* 0 0 0 0 0 0 0 32 0 1 0 0 0 0 0 1 0 0 0 0 0 0 1 33 0 1 0 0 0 0 1 2 0 0 0 0 0 1 0 34 0 1 0 0 0 1 0 3 0 0 0 0 0 1 1 35 0 1 0 0 0 1 1 4 0 0 0 0 1 0 0 36 0 1 0 0 1 0 0 5 0 0 0 0 1 0 1 37 0 1 0 0 1 0 1 6 0 0 0 0 1 1 0 38 0 1 0 0 1 1 0 7 0 0 0 0 1 1 1 39 0 1 0 0 1 1 1 8 0 0 0 1 0 0 0 40 0 1 0 1 0 0 0 9 0 0 0 1 0 0 1 41 0 1 0 1 0 0 1 10 0 0 0 1 0 1 0 42 0 1 0 1 0 1 0 11 0 0 0 1 0 1 1 43 0 1 0 1 0 1 1 12 0 0 0 1 1 0 0 44 0 1 0 1 1 0 0 13 0 0 0 1 1 0 1 45 0 1 0 1 1 0 1 14 0 0 0 1 1 1 0 46 0 1 0 1 1 1 0 15 0 0 0 1 1 1 1 47 0 1 0 1 1 1 1 16 0 0 1 0 0 0 0 48 0 1 1 0 0 0 0 17 0 0 1 0 0 0 1 49 0 1 1 0 0 0 1 18 0 0 1 0 0 1 0 50 0 1 1 0 0 1 0 19 0 0 1 0 0 1 1 51 0 1 1 0 0 1 1 20 0 0 1 0 1 0 0 52 0 1 1 0 1 0 0 21 0 0 1 0 1 0 1 53 0 1 1 0 1 0 1 22 0 0 1 0 1 1 0 54 0 1 1 0 1 1 0 23 0 0 1 0 1 1 1 55 0 1 1 0 1 1 1 24 0 0 1 1 0 0 0 56 0 1 1 1 0 0 0 25 0 0 1 1 0 0 1 57 0 1 1 1 0 0 1 26 0 0 1 1 0 1 0 58 0 1 1 1 0 1 0 27 0 0 1 1 0 1 1 59 0 1 1 1 0 1 1 28 0 0 1 1 1 0 0 60 0 1 1 1 1 0 0 29 0 0 1 1 1 0 1 61 0 1 1 1 1 0 1 30 0 0 1 1 1 1 0 62 0 1 1 1 1 1 0 31 0 0 1 1 1 1 1 63 0 1 1 1 1 1 1 Table 1. Profibus Station Address Settings 6 CTI 2500-RBC Installation and Operation Guide V1.2

Station Switch Number / State Station Switch Number / State Addres Address 4 5 6 7 8 9 10 s 4 5 6 7 8 9 10 64 1 0 0 0 0 0 0 95 1 0 1 1 1 1 1 65 1 0 0 0 0 0 1 96 1 1 0 0 0 0 0 66 1 0 0 0 0 1 0 97 1 1 0 0 0 0 1 67 1 0 0 0 0 1 1 98 1 1 0 0 0 1 0 68 1 0 0 0 1 0 0 99 1 1 0 0 0 1 1 69 1 0 0 0 1 0 1 100 1 1 0 0 1 0 0 70 1 0 0 0 1 1 0 101 1 1 0 0 1 0 1 71 1 0 0 0 1 1 1 102 1 1 0 0 1 1 0 72 1 0 0 1 0 0 0 103 1 1 0 0 1 1 1 73 1 0 0 1 0 0 1 104 1 1 0 1 0 0 0 74 1 0 0 1 0 1 0 105 1 1 0 1 0 0 1 75 1 0 0 1 0 1 1 106 1 1 0 1 0 1 0 76 1 0 0 1 1 0 0 107 1 1 0 1 0 1 1 77 1 0 0 1 1 0 1 108 1 1 0 1 1 0 0 78 1 0 0 1 1 1 0 109 1 1 0 1 1 0 1 79 1 0 0 1 1 1 1 110 1 1 0 1 1 1 0 80 1 0 1 0 0 0 0 111 1 1 0 1 1 1 1 81 1 0 1 0 0 0 1 112 1 1 1 0 0 0 0 82 1 0 1 0 0 1 0 113* 1 1 1 0 0 0 1 83 1 0 1 0 0 1 1 114* 1 1 1 0 0 1 0 84 1 0 1 0 1 0 0 115* 1 1 1 0 0 1 1 85 1 0 1 0 1 0 1 116* 1 1 1 0 1 0 0 86 1 0 1 0 1 1 0 117* 1 1 1 0 1 0 1 87 1 0 1 0 1 1 1 118* 1 1 1 0 1 1 0 88 1 0 1 1 0 0 0 119* 1 1 1 0 1 1 1 89 1 0 1 1 0 0 1 120* 1 1 1 1 0 0 0 90 1 0 1 1 0 1 0 121* 1 1 1 1 0 0 1 91 1 0 1 1 0 1 1 122* 1 1 1 1 0 1 0 92 1 0 1 1 1 0 0 123* 1 1 1 1 0 1 1 93 1 0 1 1 1 0 1 124* 1 1 1 1 1 0 0 94 1 0 1 1 1 1 0 125* 1 1 1 1 1 0 1 NOTE: The address setting on the 2500-RBC switches must match the address set for the base in WorkShop or Com Profibus for proper operation NOTE: When connecting the 2500-RBC to a 545/555/575 CPU, only addresses between 1 and 112 are valid. SW11 - Display Mode. Switch 11 controls the display mode of the LED status display to show either the station address or the module status. CTI 2500-RBC Installation and Operation Guide V1.2 7

When switch 11 is set to 1 (closed), the station address of the RBC is displayed as a three digit number, one digit at a time. There is a short pause after each digit, then a long pause after the last digit. When switch 11 is set to 0 (open), the status of the RBC is displayed according to the status codes below. Display Definition Communication s to RBC Comment / Action 0 Module Ready OK Fully Operational and Online to master. 1 Diagnostic Failure None Serious malfunction. Place system in safe state and consult CTI technical support 2 Module Mismatch OK I/O modules installed do not match the expected configuration in the master. 3 No Communications None There is no communication with the master. Place the system in a safe state. Check cabling and connection to the master. a Module Mismatch wrong module OK The wrong module is inserted into a configured slot with Simatic 505 mismatch mode disabled. A Diagnostic failure None Serious malfunction. Place system in safe state and consult CTI technical support E Diagnostic failure None Serious malfunction. Place system in safe state and consult CTI technical support. 50X Ignore Mismatch is enabled OK The. Character is turned on in conjunction with the other displayed number when the 50X Ignore Mismatch parameter is enabled. SW12 Reserved. This switch position is reserved for future use. 8 CTI 2500-RBC Installation and Operation Guide V1.2

NOTE: The Option switches are read only at module startup. If you change the switch position after startup, you must reset the module before the setting will take effect. Setting the Output State on Communications Loss When I/O channel communication to a remote base is lost, the state of the discrete outputs is determined by the selection made on the 2500-RBC jumper JP1 (Off/Freeze). Figure 2 shows the location of the jumper on the 2500-RBC. NOTE: The 2500-RBC ships with the FREEZE jumper in the OFF setting. NOTE: If the jumper JP1 is missing from the board, the 2500-RBC defaults to the OFF setting. For discrete output modules, the state of the outputs is determined solely by the position of the Off/Freeze jumper JP1 on the 2500-RBC. For analog/word output modules, the state of the outputs is influenced not only by the position of the Off/Freeze jumper but by the output module s (Zero/Hold Last Value) selection, if the module has that option. See the table below. RBC Off/Freeze Selection Analog/Word Module Zero/Hold Selection Analog/Word Output State Off Zero Zero* Off Hold Last Value Last Value Off No selection Last Value Freeze Zero Last Value Freeze Hold Last Value Last Value Freeze No selection Last Value *see the user manual of your analog/word output module for details Notice that the Freeze option on the RBC overrides the Zero selection on the analog/word output module; likewise, when Hold Last Value is selected on the analog/word output module, that selection overrides the Off option on the RBC jumper. CTI 2500-RBC Installation and Operation Guide V1.2 9

Setting Software Parameters in WorkShop or Com Profibus The 2500-RBC has parameters that are specified using the Com Profibus configuration utility software. Refer to the Chapter 3 for information about using Com Profibus. The paragraphs below describe the parameters used to set up the 2500-RBC. The Discrete I/O Interval parameter defines the rate in milliseconds at which the 2500-RBC updates I/O modules. This parameter specifies the minimum time between updates of the discrete I/O modules. Valid values are 1-255 and the default value is 1. The Word I/O Update Factor controls how often the word I/O modules are updated. The Word I/O Factor is the number of discrete I/O updates performed per word update; for example, if the factor is 2, the word I/O modules are updated on every second discrete I/O update. Valid values are 1-255 and the default value is 2. The 50X Ignore Mismatch Mode parameter allows you to select the way I/O configuration mismatches are handled. With the default setting, Disable, the 2500-RBC handles I/O configuration mismatches according to DP Standard mode, meaning that the configuration sent by the CPU to the RBC must match the actual base configuration exactly, or else no I/O updates are performed. If you enable 50X Ignore Mismatch Mode, the RBC performs updates with all modules whose configuration matches, omitting only those modules whose configuration does not match. This mode of operation does not conform to the DP Standard. For detailed information about how mismatches are indicated and handled, see Section 2.8. Configuring the Remote Base in WorkShop or Com Profibus The remote base must be configured in WorkShop or Com Profibus to describe to the Profibus Master which I/O modules are installed. In Com Profibus, this configuration is done using the Properties / Configure / Module dialog. For each slot in the base, simply select the installed CTI or Siemens I/O module from the list. For more information or if you re using WorkShop, see Chapter 3. Exporting a Binary Configuration File from Com Profibus Once the RBC has been parameterized and configured in Com Profibus, a binary file is exported which contains the configuration information. This file is used for setup of the Profibus Master. For more information, see Chapter 3. This export step is not required when using WorkShop. Merging the Configuration File into the Profibus Master The exported binary file must be merged with the Profibus Master to bring in the I/O configuration of the remote base. For more information about Merging the configuration file in Workshop (when using the 2500-RBC with CTI 2500 Series or Simatic 505 PLC s), see Chapter 3. This merge step is not required when using WorkShop. 2.5. Physical Installation To insert the module into the I/O base, hold the top and bottom of the bezel and slide the module carefully into the slot, pushing it all the way into the base. If you have inserted the module correctly, 10 CTI 2500-RBC Installation and Operation Guide V1.2

you will feel a slight increase in resistance as the module mates with the base backplane connector. Once the module is fully seated in the slot, tighten the captive screws at the top and bottom to hold the module in place. To remove the module from the I/O base, loosen the captive screws, then move the module. Take care not to damage the connector at the back of the module when inserting or removing the module. 2.6. Connecting the Profibus Cable The Profibus port is used to connect the 2500-RBC to a Profibus DP network. The Simatic 545/555/575 System Manual describes how to connect a 12 Mbaud RS-485 cable to the PROFIBUS- DP port. The figure below shows the required pinout for the DB9 Profibus port. NOTE: NOTE: Pins 2 and 7 are No Connect for the RBC. For some PROFIBUS products, these pins are used to provide 24 VDC for powering a programming or configuration tool. Such tools are not powered by the RBC; however, it is acceptable for an externally-powered PROFIBUS programming or configuration tool to drive pins 2 and 7 to 24 VDC. CAUTION: Pin 5 (BIAS SUPPLY +5V) and Pin 6 (BIAS SUPPLY GND) on the Profibus-DP connector are designed to support termination of the Profibus-DP cable only. These pins have a limited output power capability of approximately 0.45W. Overloading these pins by using the voltage CTI 2500-RBC Installation and Operation Guide V1.2 11

to drive other than the normal terminating resistors can cause internal component damage to the 2500-RBC. 2.7. Diagnostics The standard for PROFIBUS-DP I/O, DIN 19245, Part 3, stipulates the format that each DP slave shall use to report specific diagnostics to the DP master. The diagnostics used by the PROFIBUS-DP RBC are described below. NOTE: Byte 1 through Byte 15, as described in this text, correspond to Octet 1 through Octet 15 in the PROFIBUS standard. For PROFIBUS-DP I/O, Bit 7 is the most significant bit (MSB), 0 is the least significant bit (LSB). This may or may not correspond to the bit numbering scheme used in your master system. For example, CTI 2500 Series and Simatic 505/500 controllers identify the MSB of a byte as Bit 1, and the LSB of a byte as Bit 8. A DP diagnostic consists of two parts. The first part (Bytes 1 through 6) is standardized for all DP slaves. The second, or extended, part (Bytes 7 through 15 in the case of the RBC) is slave-specific. In the description that follows, it is assumed that the diagnostic has been successfully read from an RBC that has been configured and activated: that is, that Bytes 5 and 6 equal 0xBC and 0xD0, respectively. 2.8. Base Mismatch Handling in the 2500-RBC The 2500-RBC automatically detects mismatches between the Profibus configuration expected by the Profibus Master and the actual remote base configuration. Depending on the type of mismatch and the configuration settings, the 2500-RBC can operate normally or go offline and indicate a mismatch. The table below shows the response of the 2500-RBC under various conditions. 2500-RBC Mismatch Handling 50X Ignore Mismatch Mode = disabled Action Display Outputs Remove a module 2 Follow freeze jumper setting Add a module to an open slot 0 Normal operation. The inserted module is ignored. Replace a module with a different one a Follow freeze jumper setting 50X Ignore Mismatch Mode = enabled Action Display Outputs Remove a module 2. All other slots operate normally Add a module to an open slot 0. The inserted module is ignored, all other slots operate normally Replace a module with a different one 2. The inserted module is ignored, all other slots operate normally 12 CTI 2500-RBC Installation and Operation Guide V1.2

2.9. Differences Between the 2500-RBC and the 505-6870 There are minor differences between the 2500-RBC and the 505-6870 which may affect some user applications. The differences are summarized below: Display the 2500-RBC does not use the 4, 5, 6, 8, and C status codes on the display. For diagnostic failures, the 2500-RBC display codes A or E. The 2500-RBC also displays a new code a to indicate the user has an incorrect module inserted in a configured slot when 50X Ignore Mismatch is disabled. Reset switch the 2500-RBC does not include a reset switch. RS232 port the 2500-RBC includes an RS232 port, but communication with the PLC using this port is not presently implemented. Future versions of the product may contain this feature. Mismatch handling When 50X Ignore Mismatch is disabled and a module is inserted into an empty slot, the 2500-RBC ignores the inserted module and continues normal operation. The 505-6870 considers this situation a mismatch and takes the base offline. When 50X Ignore Mismatch is disabled and the wrong module is inserted into a configured slot, the 2500-RBC displays an a, takes the base offline, and sets outputs based on the freeze jumper setting. The 505-6870 displays a 2 and takes the base offline. When 50X Ignore Mismatch is enabled and a module is inserted into an empty slot, the 2500-RBC ignores the inserted module and continues normal operation. The 505-6870 displays a 2, ignores the inserted module, and continues normal operation. When Profibus is stopped from the PLC, the 2500-RBC displays a 3, sets outputs based on the freeze jumper setting, and turns inputs off. The 505-6870 displays a 3, sets outputs based on the freeze jumper setting, and leaves inputs at their last state. 2.10. Diagnostics The 2500-RBC provides diagnostic information in the PLC available in status words and through execution of the RSD instruction in the ladder logic. PLC Status Words NOTE: For more information on STW diagnostics, see the Simatic 545/555/575 Programming Reference, Appendix G. STW147: This PLC status word records the number of times, since the most recent start, that the Profibus-DP slaves have failed to respond to a request from the CPU. Each time communication is lost to the CTI 2500-RBC Installation and Operation Guide V1.2 13

2500-RBC, STW147 increments by 1. When there is a base mismatch detected by the 2500-RBC, STW147 increments continuously. STW03-STW09 These 7 status words give the status for Profibus-DP slaves. Each bit corresponds to a particular Profibus address, with STW03 Bit 16 being address 1 and STW09 Bit 1 being address 112. Each bit = 0 if the address is present and operating. The bit = 1 if the address is not present or failed. When the 2500-RBC loses communication or goes offline due to a mismatch, the corresponding bit for that address is set = 1. STW211-STW217 These 7 status words contains the enable status of each Profibus address. If the slave is enabled, the bit = 1. If the slave is disabled, the bit = 0. STW231 bits 1,2, and 16 indicate the OPERATE, CLEAR, and CONFIGURED state of the Profibus- DP I/O system. STW232-STW238 indicate the Profibus-DP slave that have signaled a diagnostic that has not been read by an RSD instruction. The slave s bit is a 1 if a diagnostic has been signaled and not yet read. Diagnostic Bytes from the 2500-RBC When an RSD instruction is executed, the 2500-RBC returns 15 bytes of information which is stored according to the settings in the RSD instruction. In each byte, bit 7 is the MSB and bit 0 is the LSB. Byte 1: Station_Status_1 Bit 7 = RBC parameterized from another master (see description of byte 4) Bit 6 = Parameterization error Bit 5 = Invalid response from RBC (always set to 0) Bit 4 = Unsupported function request from RBC Bit 3 = Extended diagnostics (bytes 7-15) present Bit 2 = Configuration error Bit 1 = RBC not ready Bit 0 = RBC did not respond Byte 2: Station_Status_2 Bit 7 = RBC is configured but not active (RBC can only set this to 0) Bit 6 = Reserved Bit 5 = RBC is operating in SYNCHRONOUS mode Bit 4 = RBC is operating in FREEZE mode Bit 3 = Reserved Bit 2 = Always set to 1 Bit 1 = Always set to 0 Bit 0 = RBC waiting for parameterization Byte 3: Station_Status_3 Bit 7 = Always set to 0 14 CTI 2500-RBC Installation and Operation Guide V1.2

Bit 6 = Reserved Bit 5 = Reserved Bit 4 = Reserved Bit 3 = Reserved Bit 2 = Reserved Bit 1 = Reserved Bit 0 = Reserved Byte 4: Diag.Master_Add Bits 7-0 contain the address of the master that has parameterized the RBC. If none of the masters has parameterized the RBC, then the RBC inserts the address 255 in this byte. Bytes 5-6: Ident_Number Manufacturer identifier for the RBC. The 2500-RBC reports BCD0 for this value. Byte 7: Ext_Diag_Data Device-related diagnostic header; value is 0x06. Byte 8: Ext_Diag_Data Bit 7 = Reserved Bit 6 = Reserved Bit 5 = Reserved Bit 4 = Reserved Bit 3 = Reserved Bit 2 = Reserved Bit 1 = Reserved Bit 0 = Remote port request pending Bytes 9-10: Ext_Diag_Data Reserved Byte 11: Ext_Diag_Data Bit 7 = Slot 8 is mismatched type Bit 6 = Slot 7 is mismatched type Bit 5 = Slot 6 is mismatched type Bit 4 = Slot 5 is mismatched type Bit 3 = Slot 4 is mismatched type Bit 2 = Slot 3 is mismatched type Bit 1 = Slot 2 is mismatched type Bit 0 = Slot 1 is mismatched type Byte 12: Ext_Diag_Data Bit 7 = Slot 16 is mismatched type Bit 6 = Slot 15 is mismatched type Bit 5 = Slot 14 is mismatched type Bit 4 = Slot 13 is mismatched type Bit 3 = Slot 12 is mismatched type Bit 2 = Slot 11 is mismatched type CTI 2500-RBC Installation and Operation Guide V1.2 15

Bit 1 = Slot 10 is mismatched type Bit 0 = Slot 9 is mismatched type Byte 13: Ext_Diag_Data Identifier-related diagnostic header; value is 0x43. Byte 14: Ext_Diag_Data Bit 7 = Slot 8 contains failed module or is mismatched type Bit 6 = Slot 7 contains failed module or is mismatched type Bit 5 = Slot 6 contains failed module or is mismatched type Bit 4 = Slot 5 contains failed module or is mismatched type Bit 3 = Slot 4 contains failed module or is mismatched type Bit 2 = Slot 3 contains failed module or is mismatched type Bit 1 = Slot 2 contains failed module or is mismatched type Bit 0 = Slot 1 contains failed module or is mismatched type Byte 15: Ext_Diag_Data Bit 7 = Slot 16 contains failed module or is mismatched type Bit 6 = Slot 15 contains failed module or is mismatched type Bit 5 = Slot 14 contains failed module or is mismatched type Bit 4 = Slot 13 contains failed module or is mismatched type Bit 3 = Slot 12 contains failed module or is mismatched type Bit 2 = Slot 11 contains failed module or is mismatched type Bit 1 = Slot 10 contains failed module or is mismatched type Bit 0 = Slot 9 contains failed module or is mismatched type 16 CTI 2500-RBC Installation and Operation Guide V1.2

CHAPTER 3. SETTING UP THE 2500-RBC USING WORKSHOP OR COM PROFIBUS 3.1. Overview Configuration of the Profibus network can be accomplished using either PLC WorkShop for Siemens 505 (version 4.32 or above) or the Com Profibus configuration utility. If you re using PLC WorkShop for Siemens 505, please refer to the PLC Memory and I/O Configuration of the WorkShop user manual for a complete discussion of Profibus network configuration. If you re using Com Profibus, follow the procedure below: The configuration utility Com Profibus is used to setup the 2500-RBC for operation with a CTI 2500 Series or Simatic 505 PLC or other Profibus master. Steps for configuration include. 1. Startup Com Profibus 2. Import 2500-RBC gsd file into Com Profibus 3. Set bus parameters 4. Add a master (CTI 2500-Cxxx or 505-CP1434-DP) to the system and set Profibus address 5. Add a 2500-RBC to the system 6. Configure the 2500-RBC a. Set address b. Set station name c. Parameterize d. Configure Slots 7. Save the Profibus configuration and Export the binary file 8. Merge the binary file in Workshop 9. Write the configuration to the bases 10. Set synchronous / asynchronous mode and Start Profibus 3.2. Startup Com Profibus To begin configuration of the 2500-RBC, start the Com Profibus application. The window should look like this: CTI 2500-RBC Installation and Operation Guide V1.2 17

3.3. Import the 2500R.gsd file into Com Profibus The next step is to copy the 2500R.gsd file into the Com Profibus directory. This file must be placed in the gsd subfolder where Com Profibus is installed on your hard drive. You can obtain the file from the CTI web site at ftp://ftp.controltechnology.com/public/download/tools/ Once the file is copied into the gsd subfolder, use File / Read in GSD Files to update Com Profibus with the new GSD file. 18 CTI 2500-RBC Installation and Operation Guide V1.2

3.4. Set Bus Parameters Next, set the Profibus speed for this installation using Configure / Set Bus Parameters. CTI 2500-RBC Installation and Operation Guide V1.2 19

The Bus Profile setting should be Profibus DP. Set the baud rate to your desired value. 3.5. Add a Master to the System and Set the Profibus Address. Next, add a master (CTI 2500-Cxxx or 505-CP1434-DP) to the system and set Profibus address. Select the proper master from the list. Click your selection and drag it over into the graphics window. 20 CTI 2500-RBC Installation and Operation Guide V1.2

Next, highlight the PLC master and right click. Then click Properties to set properties for this master. CTI 2500-RBC Installation and Operation Guide V1.2 21

Now enter the Profibus address for this master and a station name. Press OK when finished. Next, add the 2500-RBC to the system. Go to the DP Slave I/O CTI list and find the 2500- RBC. 22 CTI 2500-RBC Installation and Operation Guide V1.2

3.6. Add the 2500-RBC to the System Click on the 2500-RBC and drag it into the graphics window. 3.7. Configure the 2500-RBC Now, configure the 2500-RBC. Highlight the RBC and right click. CTI 2500-RBC Installation and Operation Guide V1.2 23

Then click on Properties to bring up the configuration dialog. Enter the desired Profibus address and station name. Then click the Parameterize button. In the parameterize dialog box, enter your desired settings for the parameters. For more information, see Setting Software Parameters in Com Profibus in Chapter 2. Press OK when finished. Next press the Configure button to set up the I/O slots. For each slot, select the installed CTI or Siemens module from the list. For blank slots, use the blank panel selection. Note that some CTI 24 CTI 2500-RBC Installation and Operation Guide V1.2

discrete I/O modules support multiple login configurations for 32, 18, or 8 points. Be sure that you select the desired configuration if you re using these modules. Next, press OK to exit the Configure screen and OK to exit the Slave Properties screen. 3.8. Save the Profibus Configuration and Export the Binary File Make sure the Master is highlighted as show below by clicking on it, then use File / Save to save your project. Then use Export / Binary File to export a binary file for merging into the PLC. Save the file in a place where you can access it later with Workshop or TISOFT. CTI 2500-RBC Installation and Operation Guide V1.2 25

3.9. Merge the Binary File in Workshop Next, start Workshop and go online with your PLC. Use PLC Utilities / PLC Configuration to get to the configuration menu. Press the Profibus I/O button to configure Profibus. 26 CTI 2500-RBC Installation and Operation Guide V1.2

The system used in this example already has one Profibus slave installed. If you have no slaves installed yet, your Slave Status area will be blank. To merge in your binary file and add the base to your configuration, click the Merge button, then select the.2bf file that your created with Com Profibus Export Binary File. Press OK and Workshop will read your file from disk and merge it into the PLC configuration. CTI 2500-RBC Installation and Operation Guide V1.2 27

3.10. Write the Configuration to the Base(s) You should already have installed the base and connected it to the Profibus. Next, click the Write All button to write the configuration out to the RBC on Profibus. You may get a notification that the I/O is not configured. If so, use the Edit Slave button to set the starting addresses of the slots in the base. Once all the I/O is addressed, use the Write All button again. You may also need to Enable and Slaves that are showing Disabled in the status list. 3.11. Select Synchronous or Asynchronous and Start Profibus Finally, use the Profibus Ops button to start Profibus ( Operate ) and set Synchronous or Asynchronous mode as desired. When Profibus is set to Operate, the base should come online in the status screen. The display on the base should show 0. 28 CTI 2500-RBC Installation and Operation Guide V1.2

CTI 2500-RBC Installation and Operation Guide V1.2 29

APPENDIX A. PROFIBUS INSTALLATION GUIDELINES These Profibus Installation Guidelines are based on the PNO Profibus Guideline, September 1998. General Installation Information Maximum number of stations Maximum number of stations participating in the exchange of user data Maximum number of stations per segment including repeaters Available data transfer rates in kbit/s Max. number of segments in series DP: 126 (addresses from 0.. 125) FMS: 127 (addresses from 0.. 126) 32 9.6, 19.2, 45.45, 93.75, 187.5, 500, 1500, 3000, 6000, 12000 According to EN 50170, a maximum of 4 repeaters are allowed between any two stations. Dependent on the repeater type and manufacturer, more than 4 repeaters are allowed in some cases. Refer to the manufacturer s technical specification for details. Cable Type The bus cable is specified in EN 50170 part 8-2 as "Cable Type A", and should comply with the parameters in the following table. Cable Type B, which is also described in EN 50170, is outdated and should no longer be used. Parameter Cable type A Characteristic impedance 35... 165 ohms at a frequency of (3-20 MHz) Operating capacity (pf/m) < 30 Loop resistance (W/km) < =110 Core diameter (mm) > 0.64 *) Core cross-section (mm²) > 0.34 *) Cable Lengths 30 CTI 2500-RBC Installation and Operation Guide V1.2

Data transfer rate9.6 19.2 45.45 93.75 187.5 500 1500 3000 6000 12 in kbit/s 000 Max segment length in meters 120 0 1200 1200 1200 1000 400 200 100 100 100 Important: In a PROFIBUS-DP/FMS installation, you must choose a data transfer rate which is supported by all devices connected to the bus. The chosen data transfer rate then determines the maximum segment lengths as shown above. The maximum admissible distance between two bus stations in each PROFIBUS network can be calculated as follows: (NO_REP + 1) * Segment length NO_REP= The maximum number of repeaters connected in series (depends on repeater type). Bus termination In order to minimize cable reflections and ensure a defined noise level on the data lines, the data transfer cable must be terminated at both ends with a terminating resistor combination as follows. Bus connectors and PROFIBUS-DP/FMS interface A bus connector is used to connect the bus cable to the PROFIBUS device. Bus connectors are available with a variety of protection classes and mechanical designs. The choice of connector is mainly determined by the space available in the vicinity of the PROFIBUS device (i.e. PC interface, PLC or special fieldbus device). EN 50170 Volume 2 recommends the use of a 9-pin Sub-D connector. Depending on the required protection class and the application of the fieldbus device, other connector designs are also allowed. The table below shows the pin assignment if a 9-pin Sub-D connector is used: Pin no. Signal Significance CTI 2500-RBC Installation and Operation Guide V1.2 31

1 Shield Shield/functional ground 2 M24 Ground for +24 V output voltage 3 RxD/TxD-P *) Receive/Transmit data plus (B wire) 4 CNTR-P Repeater control signal (direction control), RTS signal 5 DGND *) Data ground (reference potential for VP) 6 VP *) Supply voltage - plus (P5V) 7 P24 Output voltage +24 V 8 RxD/TxD-N *) Receive/Transmit data minus (A wire) 9 CNTR-N Repeater control signal (direction control) Make sure that the connector type used is suitable for the selected baud rate. To prevent EMC interference from entering the device, the cable shield should be connected to the functional ground of the device (generally the electrically conductive case). This is done by connecting the cable shield to the metal case of the Sub-D connector and the functional ground over a large area. The bus connector must have a low-impedance connection to the cable shield. The data transfer technology of the serial bus system, which uses a shielded twisted pair data cable, is described in the specification of the interference-immune RS 485 interface standard. To allow correct bus termination, each station must connect the signals DGND and VP (5 V) to pins 5 and 6 of the connector, respectively. The 5 V supply for the terminating resistors (VP) should have a minimum current rating of 10 ma (the current load can increase to 12 ma if a NULL signal is sent through the bus).the current rating should be increased to app. 90 ma if you need to be able to supply other types of devices on the bus such as bus terminals and optical fiber cable drivers. Due to the capacitive load of the station and the resulting cable reflections, bus connectors should be provided with built-in series inductors as shown below. Due to the built-in series inductors in the bus connectors, all bus connectors in the network should be attached to fieldbus devices to ensure that the necessary capacitive load is provided by the device input capacitance. 32 CTI 2500-RBC Installation and Operation Guide V1.2

Cable laying guidelines Laying of copper cable Data transfer in PROFIBUS systems is based on an interference-immune symmetrical bus system to the RS 485 specification using shielded twisted pair cable. With correct system installation, small external sources of interference are led to ground through the cable shield without causing interference in the data lines. Interference of this type can largely be avoided with appropriate EMC measures such as EMCcompliant system installation, EMC-compliant cable laying and measures that avoid large ground potential differences. Electromagnetic interference from sources such as switching processes, rectifiers and circuit breakers can cause equipment faults to occur. In addition, overvoltage and lightning strikes can destroy electronic components in fieldbus devices. Correct operation of the plant can then no longer be guaranteed. Particularly for equipment containing frequency inverters (variable speed drives), the manufacturer s regulations for EMC compliance must be observed for the following components: Filters, Chokes, and CTI 2500-RBC Installation and Operation Guide V1.2 33

Shielding. In addition, electronic starters should be used if fluorescent lamps are installed within control cabinets. The following cable laying instructions apply to shielded twisted pair cables. The cable shield is used to improve the immunity to electromagnetic interference. PROFIBUS cables should be shielded with a combination of both conductive braid and conductive foil. In the following, "shield" refers to both types of shields (braid and foil). A foil shield should not be used on its own, because it is very thin and can easily be damaged. The cable shield must be connected to the functional ground at both ends of the cable by making a large-area connection to a grounded conductive surface. When laying the bus cables, particular care should be taken to ensure that the cable shield (braid shield and foil shield, if available) is connected to the shield grounding clamp over a large area. The two PROFIBUS data lines are designated A and B. There are no regulations on which cable core color should be connected to which of the two data terminals on each fieldbus device; the sole requirement is to ensure that the same core color is connected to the same terminal (A or B) for all stations throughout the entire system (across all stations and bus segments). If the data transfer cable has data wires with red and green insulation, then the following assignment should be used: Data cable wire A - green Data cable wire B red This rule applies to both the incoming and the outgoing data lines. Laying cables within control cabinets If a repeater or fieldbus device is installed within a control cabinet, the cable shield of the incoming bus cable should be electrically connected to a grounding rail as close as possible to the cable leadthrough using a shield grounding clamp or similar (see Figure 3-1). The cable shield should continue within the cabinet to the fieldbus device and be connected there in accordance with the manufacturer s instructions. The following installation guidelines should be observed. Ensure that the case of the device and also the control cabinet in which the fieldbus device is mounted have the same ground potential by providing a large-area metallic contact to ground (use e.g. galvanized steel to ensure a good connection). Grounding rails should not be attached to painted surfaces. If the above measures are observed, electromagnetic interference is diverted through the cable s shield. 34 CTI 2500-RBC Installation and Operation Guide V1.2

PROFIBUS cables... and cables for... must be laid... Bus signals, e.g. PROFIBUS Data signals for PC s, programming devices, printers etc. Screened analog inputs Unscreened DC voltages (<= 60V) Screened process signals (<= 25 V) Unscreened AC voltages (<= 25V) Coaxial cables for monitors DC voltages from 60 V... 400 V (unscreened) AC voltages from 25V... 400 V (unscreened) DC and AC voltages > 400 V (unscreened) Telephone cables For areas with explosion hazard in the same cable loom or cable duct. in separate cable looms or cable ducts without minimum spacing requirements in separate cable looms or cable ducts without minimum spacing requirements Laying cables outside of control cabinets All cable ducts should be constructed of electrically conducting material and connected to functional ground at regular intervals. Bus cables should not be subject to mechanical loads which exceed the manufacturer s specifications. If this cannot be avoided, additional protective measures should be taken, e.g. by laying the cables in a steel pipe or rugged metal duct. The pipe or duct should then be grounded at regular intervals and protected against corrosion. CTI 2500-RBC Installation and Operation Guide V1.2 35

SPECIFICATIONS General Module Size: Double-Wide CTI 2500 Series or Simatic 505 I/O Backplane Power Consumption: 2.5 watts Compatibility: CTI 2500 Series, Simatic 505, Siemens S5 and S7 masters Compatibility: all currently-available CTI and Siemens 4-, 8-, and 16-slot bases Display: shows errors codes and Profibus address Output State Selection: Determines state of outputs when I/O channel communication is lost: off all outputs are turned off freeze all outputs hold their last value Dipswitch Options: Serial port baud rate (future use) RBC station address Status display mode Software-Set Parameters: Discrete I/O interval Word I/O update factor Ignore mismatch mode RS232 port enable/disable Diagnostic Data: Station status (3 bytes) Master address (1 byte) Ident number (1 byte) Extended diagnostics (9 bytes) Ports Profibus: 9-pin female, pins 2,7 no connect Communication Speeds Supported: 9600, 19.2K, 93.75K, 187.5K, 1.5M, 3.0M, 6.0M, 12M RS232C: 9-pin male, future use Profibus Port Isolation: 1500VDC Environmental Operating Temperature: 0º to 60º C (32º to 185º F) 36 CTI 2500-RBC Installation and Operation Guide V1.2

Storage Temperature: -40º to 85º C (-40º to 185º F) Humidity: 5% to 95%, non-condensing Agency Approvals Pending: UL, ULC, CE Shipping Weight: 1.5 lb. (0.68 Kg) CTI 2500-RBC Installation and Operation Guide V1.2 37

LIMITED PRODUCT WARRANTY CTI warrants that this CTI Industrial Product shall be free from defects in material and workmanship for a period of one (1) year after purchase from CTI or from an authorized CTI Industrial Distributor. This CTI Industrial Product will be newly manufactured from new and/or serviceable used parts which are equal to new in the Product. Should this CTI Industrial Product fail to be free from defects in material and workmanship at any time during this (1) year warranty period, CTI will repair or replace (at its option) parts or Products found to be defective and shipped prepaid by the customer to a designated CTI service location along with proof of purchase date and associated serial number. Repair parts and replacement Product furnished under this warranty will be on an exchange basis and will be either reconditioned or new. All exchanged parts or Products become the property of CTI. Should any Product or part returned to CTI hereunder be found by CTI to be without defect, CTI will return such Product or part to the customer. This warranty does not include repair of damage to a part or Product resulting from: failure to provide a suitable environment as specified in applicable Product specifications, or damage caused by an accident, disaster, acts of God, neglect, abuse, misuse, transportation, alterations, attachments, accessories, supplies, non-cti parts, non-cti repairs or activities, or to any damage whose proximate cause was utilities or utility like services, or faulty installation or maintenance done by someone other than CTI. Control Technology Inc. reserves the right to make changes to the Product in order to improve reliability, function, or design in the pursuit of providing the best possible Product. CTI assumes no responsibility for indirect or consequential damages resulting from the use or application of this equipment. THE WARRANTY SET FORTH ABOVE IN THIS ARTICLE IS THE ONLY WARRANTY CTI GRANTS AND IT IS IN LIEU OF ANY OTHER IMPLIED OR EXPRESSED GUARANTY OR WARRANTY ON CTI PRODUCTS, INCLUDING WITHOUT LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE AND IS IN LIEU OF ALL OBLIGATIONS OR LIABILITY OF CTI FOR DAMAGES IN CONNECTION WITH LOSS, DELIVERY, USE OR PERFORMANCE OF CTI PRODUCTS OR INTERRUPTION OF BUSINESS, LOSS OF USE, REVENUE OR PROFIT. IN NO EVENT WILL CTI BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES. SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR CONSUMER PRODUCTS, SO THE ABOVE LIMITATIONS OR EXCLUSIONS MAY NOT APPLY TO YOU. THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH MAY VARY FROM STATE TO STATE. 38 CTI 2500-RBC Installation and Operation Guide V1.2